Spring and molded cushion



Jan. 19, 1965 K. P. Ross 3,165,761

SPRING AND MOLDED CUSHION Filed July 27 1962 ATTORNEY United States Patent O 3,l65,76l SlRlNG AND MLBED {CUSHHN Kenneth l?. Ross, 333e Washhurn Ave. S.,

Y Minneapolis, Minno Filed .luly 27, i962, Ser. No.. 212,957 Claims. (Cl. -=35l) This invention relates to a novel cushion for furniture items or the like, and more particularly to a cushion wherein a spring core is uniquely combined with a surrounding casing of a foam or sponge material in a unique manner whereby the resulting cushion possesses good resilient and elastic characteristics, affording a soft padding, yet is suliiciently sturdy so that it cannot be unduly cornpressed when bearing a normal load.

Another object of the invention is to provide a novel means giving positive station to all parts of the spring core to retain the spring core properly disposed with respect to its surrounding foam encasernent, even after a long period of use of the cushion, to insure that the spring core will not be felt by the user.

Still a further object of the invention is to provide a novel cushion construction wherein the center portion of the cushion, although resilient, will possess less resiliency than the exterior portion of the cushion.

Various other objects and advantages of the invention will hereinafter become more fully apparent from the following description of the drawing, illustrating a presently preferred embodiment thereof, and wherein:

FIGURE 1 is a plan view, partly in section and partly broken away, showing a cushion constructed in accordance with the invention;

FIGURE 2 is a fragmentary cross sectional view thereof;

FIGURE 3 is an enlarged fragmentary transverse sectional view taken substantially along a plane as indicated by the line 3--3 of FIGURE 1, through va part of the cushion;

FlGURE 4 is a fragmentary sectional View taken substantially along the line 4 4 of FIGURE 3, and

FIGURE 5 is an enlarged fragmentary sectional View of a part of the structure shown in FIGURE 4.

Referring more specifically to the drawing, the cushion in its entirety and comprising the invention is designated generally 7 and is broadly composed of a spring core unit, designated generally S, and a surrounding encasernent 9 of a molded foam or sponge material.

The resilient core unit includes a plurality of coiled springs lll, each of which is enclosed in a separate fabric casing ll. Each casing il includes a cylindrical side wall l2 and end Walls 13 which are integrally joined to the ends of the cylindrical side wall. The coiled springs lli, each enclosed in its casing ll, are enclosed by an outer fabric casing i4 which fits snugly around the springs lill. Said outer casing 14 includes normally substantially parallel walls l5 between which the springs it) are disposed with their axes perpendicular to said walls l5, and a surrounding wall 16 which is integrally connected to the marginal edges of the walls l5.

As best illustrated in FIGURE 3, the adjacently disposed springs 10 and the casings lil thereof are connected to one another and to the walls l5 of the outer casing ll4 by suitable connecting means, shown in the drawing as hog rings i7; however, other connecting means such as stitching may be utilized. The portions of the hog rings il?, which protrude from the exteriors of each of the walls l5, are connected to one another by cords i8 which combine with said hog rings i7, the outer casing 14 and the individual inner spring casings lll to effectively tie the springs l0 together to prevent movement of said springs ice relative to one another except in directions coinciding with he axes of said springs. The casings lil and ld are each composed of a wide or loose weave fabric, such as muslin.

The outer foam or sponge encasement 9 of the cushion 7 may be formed of any suitable material which is molded by pressure such as urethane or polyester foams. The material of which the encasernent il is formed is molded under pressure in any conventional manner around the core unit S. During the molding operation and before the material constituting the encasement 9 has set, said material will seep through the walls l5, as seen at 9 in FEGURE 3, and also through the end walls i3 which abut the inner sides of said walls l5. Additionally, as seen at 9 in FIGURES 3, 4 and 5, a partof the foam material will seep through the surrounding wall le and through the parts of the walls l2, which contact said wall l. Accordingly, when the material forming the encasement 9 has set, said encasement will be effectively bonded to all parts of the fabric casing ld and to each of the individual spring casings il to insure and effectively maintain a positive station for each of the springs lil.

The resilient core unit 3 possesses less resiliency and elasticity than the surrounding foam encasement 9 so that the cushion 7 will possess a desired degree of stiffness in an area disposed approximately midway between its opposite surfaces 19 and 2d and a greater degree of elasticity and resiliency, adjacent said surfaces 19 and 2i).

lt will be understood that the cushion 7 may be made in various sizes and shapes such as an individual seat cushion or of a size to provide a mattress.

Various modications and changes are contemplated and may obviously be resorted to Without departing from the function or scope of the invention as hereinafter defined bythe appended claims.

l claim as my invention:

l. A cushion comprising a resilient core unit including a plurality of coiled springs, a fabric casing enclosing all of said springs, and a one piece outer encasement of a pressure molded foam material completely enclosing said fabric casing, said fabric casing being of a loose weave material and having parts of the pressure molded foam material embedded therein and bonded thereto.

2. A cushion as in claim 1, said core unit including individual fabric casings each enclosing one of said springs, said individual fabric casings being enclosed by said first mentioned fabric casing and each having wall portions in contact therewith and of a loose weave material in which parts of the foam material are embedded for anchoring each of the individual spring casings to said first mentioned casing and to said foam encasement'.

3. A cushion as in claim 2, and means connecting the end convolutions of `the adjaccntly disposed springs to one another, said means connecting the individual casings to one another and to said iirst mentioned casing and including portions embedded in said molded encasernent.

4. A cushion as in claim 3, said connecting means comprising hog rings.

5. A cushion as in claim 4, and cords engaging through and connecting portions of said hog rings which are disposed externally of said first mentioned fabric casing.

References Cited bythe Examiner UNITED STATES PATENTS 2,385,870 lO/45 Lashar et al 5-353 X 2,446,775 8/48 Marsack 5--353 2,681,457 l/54 Rymland 5-351 2,882,959 4/59 Burkart 5-353 X 3,070,814 1/63 Witholf 5-351 X FRANK B. SHERRY, Primary Examiner. 

1. A CUSHION COMPRISING A RESILIENT CORE UNIT INCLUDING A PLURALITY OF COILED SPRINGS, A FABRIC CASING ENCLOSING ALL OF SAID SPRINGS, AND A ONE PIECE OUTER ENCASEMENT OF A PRESSURE MOLDED FOAM MATERIAL COMPLETELY ENCLOSING SAID FABRIC CASING, SAID FABRIC CASING BEING OF A LOOSE WEAVE MATERIAL AND HAVING PARTS OF THE PRESSURE MOLDED FOAM MATERIAL EMBEDDED THEREIN AND BONDED THERETO. 